Rerouting of Heater Hoses{1812, 7304} Caterpillar

Rerouting of Heater Hoses{1812, 7304}

Usage:

735B L4D

Articulated Truck:: 735B (S/N: L4D1-UP; T4P1-UP); 740B (S/N: L4E1-UP; T4R1-UP); 740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

Introduction

This Special Instruction outlines the procedure for rerouting the cab heater hose along the top of the engine to a position along the bottom of the engine.

Do not perform the procedures that are outlined in this Special Instruction until you understand the information that is contained in this document.

Reference

ReferenceOperation and Maintenance Manual "Hood Control"

ReferenceOperation and Maintenance Manual "Cooling System Coolant (ELC) - Change"

Rerouting of Heater Hose for 735B (S/N: T4P1-UP), 740B (S/N: T4R1-UP) and 740B EJECTOR (S/N: T4S1-UP) with Tier 4 Engines

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Table 1
Required Parts
Item	Qty	Part Number	Description
1	1	5P-4499	O-Ring Adapter
1	1	6V-5063	O-Ring Seal
2	1	6V-8245	Elbow
2	1	6V-9027	O-Ring Seal
3	1	8T-4195	Bolt
4	1	168-8806	Connector
4	1	3K-0360	O-Ring Seal
5	1	194-7631	Elbow
6	1	5P-8874	Adapter
6	1	3J-1907	O-Ring Seal

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Table 2
Consumables
Qty	Name	Size
1	Loctite 572 Thread Sealant	50 mL (1.7 oz)

Raise the hood fully. Refer to Operation and Maintenance Manual "Hood Control". Lower the transmission guard. Drain the cooling system coolant. Refer to Operation and Maintenance Manual "Cooling System Coolant (ELC) - Change". If the engine and emissions package is hot, allow the components to cool before working in the area of the hoses.

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Illustration 1	g03368428
(A) P-Clip (B) Hose (C) Shutoff Valve

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Illustration 2	g03368429
(B) Hose (C) Shutoff Valve (D) Hose (E) Elbow Adaptor

Disconnect Hose (B) from Shutoff Valve (C). Remove the bolts and washers that secure P-Clip (A) to the engine. Discard the bolts, washers, and P-Clip

Disconnect Hose (D) from Elbow Adaptor (E). Remove Shutoff Valve (C) and the Elbow Adaptor from the engine. Retain the Shutoff Valve and discard all the other components.

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Illustration 3	g03368430
(D) Hose (F) P-Clip

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Illustration 4	g03368432
(D) Hose (G) Adapter (H) Elbow Adaptor

Disconnect Hose (D) from Elbow Adaptor (H). Remove the bolt and washer that secures P-Clip (F) to the engine and remove the hose. Remove the elbow adapter and Adapter (G) that is in the engine from the machine and discard the components.

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Illustration 5	g03368434
(1) 5P-4499 O-Ring Adapter (2) 6V-8245 Elbow

Apply thread sealant to the threads of Adaptor (1) and Elbow (2). Install the adaptor into the port previously used by Adaptor (G). Install the elbow adaptor into the adaptor and roughly orient the elbow adaptor to the bottom front corner of the engine.

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Illustration 6	g03368436
(B) Hose (J) P-Clip (K) P-Clip (L) Hose

Remove cable straps that secure Hose (B). Remove the bolt and washer that secure P-Clip (J) for Hose (B) to the engine. Remove the bolt and washer that secures P-Clip (K) for Hose (L) to the engine. Leave the P-clips on the hoses. Retain one washer.

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Illustration 7	g03368437
(3) 8T-4195 Bolt (B) Hose (J) P-Clip (K) P-Clip (L) Hose

Reroute Hose (B) along the same route as Hose (L). Secure both P-Clip (J) and P-Clip (K) to the engine with Bolt (3) and washer retained from an earlier step. Do not tighten the bolt at this step in order to allow the routing of the hoses to be adjusted. Install suitable cable straps to secure the hoses together.

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Illustration 8	g03368438
(L) Hose (M) Nut (N) Elbow Adaptor (P) Adaptor (Q) Elbow Adaptor (R) Hose

Disconnect Hose (L) from Elbow Adaptor (N). Move the end of the hose to one side. Remove the elbow adaptor from Nut (M). Discard Elbow Adaptor (N). Leave Nut (M) in the engine.

Disconnect Hose (R) from Elbow Adaptor (Q). Remove the elbow adaptor and Adaptor (P) from the engine and discard the elbow adaptor and the adaptor.

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Illustration 9	g03368439
(3) 8T-4195 Bolt (4) 168-8806 Connector (5) 194-7631 Elbow (6) 5P-8874 Adapter (B) Hose (C) Shutoff Valve (L) Hose (M) Nut

Apply thread sealant to the threads of Shutoff Valve (C) that was retained earlier. Install the shutoff valve into Nut (M). Connect Hose (L) to the shutoff valve and orientate the shutoff valve to suit the routing of the hose. Tighten the shutoff valve in position.

Apply thread sealant to the threads of Adapter (6). Install the adaptor into the port previously used by elbow adaptor (P).

Apply thread sealant to the threads of Elbow Adaptor (5) and Connector (4). Install Connector (4) into Elbow Adaptor (5) before installing the elbow adaptor into Adapter (6). Orientate the elbow adaptor roughly towards the rear of the engine. Do not tighten the elbow adaptor in position.

Connect Hose (B) to Connector (4) on Elbow Adaptor (5). Adjust the orientation of the elbow adaptor to suit the routing of the hose. Tighten the elbow adaptor in position.

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Illustration 10	g03368864
(3) 8T-4195 Bolt (B) Hose (J) P-Clip (K) P-Clip (L) Hose

Check the routing of Hose (B) and Hose (L) through P-Clip (J) and P-Clip (K). Tighten Bolt (3) and washer that secures the P-Clips in place.

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Illustration 11	g03368442
(2) 6V-8245 Elbow (R) Hose

Connect Hose (R) to Elbow Connector (2). Adjust the orientation of the elbow adaptor. Tighten the elbow connector in position.

Refill the cooling system coolant. Refer to Operation and Maintenance Manual "Cooling System Coolant (ELC) - Change". Check for any signs of coolant leaks and correct as required.

Start the engine and allow the engine to run. Observe for coolant leaks. Turn off the engine. If there are any leaks, let the engine, emissions package, and engine coolant cool down before correcting the leaks.

Lower the hood. Refer to Operation and Maintenance Manual "Hood Control". Raise the transmission guard.

Rerouting of Heater Hose for 735B (S/N: L4D1-UP), 740B (S/N: L4E1-UP) and 740B EJECTOR (S/N: L4F1-UP) with Tier 2 Engines

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Table 3
Required Parts
Item	Qty	Part Number	Description
1	1	9S-8008	O-Ring Plug
1	1	6V-5063	O-Ring Seal
2	1	8T-4195	Bolt
3	1	5P-8874	Adapter
3	1	3J-1907	O-Ring Seal
4	1	194-7631	Elbow
5	1	168-8806	Connector
5	1	3K-0360	O-Ring Seal

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Table 4
Consumables
Qty	Name	Size
1	Loctite 572 Thread Sealant	50 mL (1.7 oz)

Raise the hood fully. Refer to Operation and Maintenance Manual "Hood Control". Drain the cooling system coolant. Refer to Operation and Maintenance Manual "Cooling System Coolant (ELC) - Change". If the engine and exhaust are hot, allow the components to cool before working in the area of the hoses.

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Illustration 12	g03368443
(A) Shutoff Valve (B) P-Clip (C) Hose (D) Elbow Adaptor (E) Hose

Disconnect Hose (C) from Shutoff Valve (A). Remove the bolts and washers that secure P-Clip (B) to the engine. Discard the bolts, washers, and P-Clip.

Disconnect Hose (E) from Elbow Adaptor (D). Remove Shutoff Valve (A) and the elbow adaptor from the engine. Retain the shutoff valve and discard the elbow adaptor.

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Illustration 13	g03368444
(E) Hose (F) P-Clip (G) Elbow Adaptor (H) Nut

Disconnect Hose (E) from Elbow Adaptor (G). Remove the bolt and washer that secures P-Clip (F) to the engine and remove the hose. Remove the elbow connector and Nut (H) from the engine. Discard all the components.

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Illustration 14	g03368446
(1) 9S-8008 O-Ring Plug

Apply thread sealant to the threads of Plug (1). Install the plug into the port that was previously used by Nut (H) .

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Illustration 15	g03368448
(C) Hose (J) P-Clip (K) P-Clip (L) Hose

Remove cable straps that secure Hose (C). Remove the bolt and washer that secure P-Clip (J) for Hose (C) to the engine. Remove the bolt and washer that secures P-Clip (K) for Hose (L) to the engine. Leave the P-clips on the hoses. Retain one washer.

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Illustration 16	g03368907
(2) 8T-4195 Bolt (C) Hose (J) P-Clip (K) P-Clip (L) Hose

Reroute Hose (C) along the same route as Hose (L). Secure both P-Clip (J) and P-Clip (K) to the engine with Bolt (2) and washer retained from an earlier step. Do not tighten the bolt at this step in order to allow the routing of the hoses to be adjusted. Install suitable cable straps to secure the hoses together.

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Illustration 17	g03368450
(L) Hose (M) Nut (N) Elbow Adaptor (P) Plug

Disconnect Hose (L) from Elbow Adaptor (N). Remove the elbow adaptor from Nut (M) and discard the elbow adaptor. Remove Plug (P) and discard the plug.

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Illustration 18	g03368451
(3) 5P-8874 Adapter (4) 194-7631 Elbow (5) 168-8806 Connector (A) Shutoff Valve (C) Hose (L) Hose (M) Nut

Apply thread sealant to the threads of Shutoff Valve (A) that was retained earlier. Install the shutoff valve into Nut (M) previously used by the Elbow Adaptor (N). Connect Hose (L) to the shutoff valve and orientate the shutoff valve to suit the routing of the hose. Tighten the shutoff valve in position.

Apply thread sealant to the threads of Adapter (3). Install the adaptor into the port previously used by Plug (P).

Apply thread sealant to the threads of Elbow Adaptor (4) and Connector (5). Install the adaptor into the elbow adaptor. Install the elbow adaptor into Adapter (3) on the engine. Orientate the elbow adaptor roughly towards the rear of the engine. Do not tighten the elbow adaptor in position.

Connect Hose (C) to Connector (5) on Elbow Adaptor (4). Adjust the orientation of the elbow adaptor to suit the routing of the hose. Tighten the elbow adaptor in position.

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Illustration 19	g03368940
(C) Hose (J) P-Clip (K) P-Clip (L) Hose

Check the routing of Hose (C) and Hose (L) through P-Clip (J) and P-Clip (K). Tighten the bolt and washer that secures the P-Clips in place.

Refill the cooling system coolant. Refer to Operation and Maintenance Manual "Cooling System Coolant (ELC) - Change". Check for any signs of coolant leaks and correct as required.

Start the engine and allow the engine to run. Observe for coolant leaks. Turn off the engine. If there are any leaks, let the engine, exhaust, and engine coolant cool down before correcting the leaks.